National Products BW3 Installation, Start-Up, And Operating Instructions Manual

Series b gas-fired induced-draft hot water boilers

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Installation, Start-Up, and Operating Instructions

Gas-Fired

Induced-Draft Hot Water Boilers

Sizes 42,500 through 225,000

NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler.

This symbol

indicates a change since the last issue.

Index

SAFETY CONSIDERATIONS.....................................................................................................................................................................................2

INTRODUCTION..........................................................................................................................................................................................................3

BOILER RATINGS AND CAPACITIES.................................................................................................................................................................3-4

LOCATING THE BOILER .......................................................................................................................................................................................4-5

FRESH AIR FOR COMBUSTION...........................................................................................................................................................................5-6

Boiler Located in Unconfined Space.......................................................................................................................................................................5

Boiler Located in Confined Space .......................................................................................................................................................................5-6

INSTALLATION-SYSTEM PIPING .....................................................................................................................................................................6-7

For Use with Cooling Units.....................................................................................................................................................................................7

Low Design Water Temperature Systems (Below 140°F) .....................................................................................................................................7

Form: IM-BW3A-05

A PP R O VED

MODEL BW3

Cancels: IM-BW3A-04

ama

A95465

Printed in U.S.A.

8-99

Series B

ASME

Catalog No. 63BW-3A1

BW3

Page

Table of Contents

Summary of Contents for National Products BW3

Page 1: Table Of Contents
Sizes 42,500 through 225,000 ® A PP R O VED NOTE: Read the entire instruction manual before starting the installation. These instructions must be affixed on or adjacent to the boiler. This symbol indicates a change since the last issue.
Page 2: Safety Considerations
CHIMNEY AND VENT PIPE CONNECTION ...7-9 Checking Chimney...8 Minimum Vent Pipe Clearance ...8 Removing Existing Boiler from Common Venting System...9 OPTIONAL HORIZONTAL VENTING WITH POWER VENTER ...9-10 GAS SUPPLY PIPING ...10-11 Checking Gas Supply ...10 Connecting Gas Piping...10-11 Checking Gas Piping ...11 ELECTRICAL WIRING...12...
Page 3: Introduction
IV Standards for cast iron heating boilers. Check to be sure boiler size is correct before starting installation. See rating and capacity table shown in Fig. 1. Also be sure new boiler is for the type of gas being used. Check rating plate on right side of boiler.
Page 4: Boiler Ratings And Capacities
6. Determine boiler room size. Rooms that are large in comparison with the size of boiler are defined as rooms having a volume equal to or greater than 16 times the volume of the boiler. Where room ceiling height is greater than 8 ft, volume of room shall be figured on the basis of 8 ft ceiling height.
Page 5: Fresh Air For Combustion
You must provide for enough fresh air to assure proper combustion. The fire in the boiler uses oxygen. It must have a continuous supply. The air in a house contains only enough oxygen to supply the burner for a short time. Outside air must enter the house to replace the oxygen used by the burner.
Page 6: Boiler Located In Confined Space
2B or shall be specially engineered. The authority having jurisdiction must approve specially engineered installations. PROCEDURE 2—BOILER LOCATED IN CONFINED SPACE EXAMPLE 2A: ALL AIR FROM INSIDE THE BUILDING The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space.
Page 7: Installation-System Piping
PROCEDURE 1—FOR USE WITH COOLING UNITS When this boiler is used in connection with refrigeration systems, it shall be installed so that the chilled medium is piped in parallel with the heating boiler. Appropriate valves must be used to prevent the chilled medium from entering the heating boiler. (See Fig. 4.) When this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, the piping system shall be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycles.
Page 8: Minimum Vent Pipe Clearance
Fig. 4—Piping Arrangements for Boiler Used in Connection with Refrigeration System 2. The boiler’s induced draft blower has a 3-in. outlet. A 3-in. X 4-in. increaser fitting is included in the parts bag. Locate increaser fitting on outlet of induced draft blower and secure gastight with a bead of the factory-supplied silicone sealant. The increaser fitting is required on this boiler for Category I venting, and 4 in.
Page 9: Removing Existing Boiler From Common Venting System
PROCEDURE 3—REMOVING EXISTING BOILER FROM COMMON VENTING SYSTEM When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
Page 10: Gas Supply Piping
PROCEDURE 1—CHECKING GAS SUPPLY The gas pipe to boiler must be the correct size for length of run and for total Btuh input of all gas utilization equipment connected to it. See Table 5 for proper size. Be sure gas line complies with local codes and gas company requirements.
Page 11: Checking Gas Piping
The boiler, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction, or in the absence of such requirements, with the NEC. Run a 14 gage or heavier copper wire from boiler to a grounded connection in service panel or a properly driven and electrically grounded ground rod.
Page 12 SPARK 24V-GND MV/PV —12—...
Page 13: Equipment And Optional Accessories
PROCEDURE 1—RELIEF VALVE A relief valve must be installed on boiler. Water expands as it is heated. If there is no place for water to expand into, water pressure builds up inside boiler and system. Should this happen, relief valve automatically opens at a predetermined pressure. This relieves strain on boiler and system.
Page 14: Circulating Pump
PROCEDURE 1—HOW A HOT WATER SYSTEM OPERATES The entire heating system (boiler, piping, and radiation units) is filled with water. As water in boiler is heated, it is pumped from top of boiler through supply main to radiation units. The cooler water in them flows back through return main to boiler. This provides positive and rapid response to thermostat.
Page 15: Gas Valve Operating Instructions
BEFORE OPERATING, smell all around appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WARNING: IF YOU SMELL GAS: • Do not attempt to operate any appliance; do not touch any electric switch; do not use any phone in your building. •...
Page 16: Checking And Adjusting
PROCEDURE 6—SAFETY CONTROLS CHECK After setting limit control to desired setting, check to see if it shuts off gas supply to burners. Set thermostat to call for heat and let boiler run until temperature of water reaches limit setting. Gas valve should shut off and circulator should keep running until thermostat is satisfied or water cools enough to restart burners through limit control.
Page 17: Maintaining Boiler
A high boiler temperature accompanied by unusually low radiation unit temperature (and "knocking") indicates excess air in tank. To correct either condition, close valve between boiler and tank. Drain tank until it is empty. Check all tank plugs and fittings. Tighten as necessary.
Page 18: Blower
Check flame. If it is yellow, burner is not getting enough air. If flame is blue and noisy and seems to lift off Burner is not operating properly the burner, burner is getting too much air. Contact your service technician. No electric power to boiler Check overcurrent protection. Check to be sure electric power supply circuit is on. Controls out of adjustment Reset according to instructions.
Page 19: Repair Parts
When ordering parts, first obtain the Model No. from the data plate on boiler, then determine the Part No. (not the Key No.) and the Description of each part from the following illustrations and lists. Be sure to give all this information: The Part No. — The Part Description — The Boiler Model No.
Page 20: Repair Parts
DESCRIPTION 24-v Gas Valve, Propane Gas Pilot Tube 10-32 X 3/16-in. Slotted Hex Head Screw Gas Manifold Orifice — Propane Gas* Main Burner Less Pilot Bracket† Main Burner with Pilot Bracket Pilot Burner with Orifice, Propane Gas ‡ Rollout Shield Quantity is 1 unless otherwise noted.
Page 21 Jacket—Section and Base Parts DESCRIPTION Jacket, Right Side Panel Blower Cover Plate Rating Plate Jacket Tie Bar Boiler Base Base Side (2 Required) Base Insulation Base Front Base Rear Nipple, Boiler Jacket, Left Side Panel Jacket, Front Panel 1/4-in. Tie Rod (2 Required)
Page 22 1/4-in. Close Nipple 1/4-in. Coupling 400°F Black Silicone Rubber Adhesive Sealant (10.3 oz cartridge) 3-in. X 4-in. Increaser Fitting — Galvanized * Not illustrated. REPAIR PARTS BOILER CONTROLS AND PIPING DESCRIPTION 2, 3, 4, 5 Section 6, 7 Section —22— PART NO.
Page 23 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including: • Unit Familiarization • Installation Overview A large selection of product, theory, and skills programs is available, using popular video-based formats and materials.

This manual is also suitable for:

Series b